Intelligent Ingredients
How smart manufacturing can help
improve yield, productivity and efficiency
in food and beverage operations
Heat.
Living in a pressure cooker
Think about the challenges your company
faces today. What comes to mind?
More quickly responding to changing markets
and consumer tastes? Meeting the needs of
consumers who are more connected, informed
and outspoken? Contending with new
competitors, like online food providers,
specialty producers or supermarket brands?
Complying with new regulations for greater
food traceability?
Clearly, this is not the food and beverage industry
of yesterday. It is more complex, consumerdriven and fast-changing.
Despite all these pressures, your production
operations must keep up if you want to
remain competitive. A key part of this means
improving productivity and efficiencies – not in
a once-and-done fashion but continually and
across your operations.
Food and Beverage Industry | 2
Rise.
The rise of Smart Manufacturing
Luckily, the manufacturing world is also rapidly
evolving. Connected, information-enabled
manufacturing – or smart manufacturing –
is creating new opportunities to help you
better understand your operations and get
more from them.
people, data and assets. This can help you
improve real-time collaboration, continuously
optimize processes and keep operations
moving, even as you contend with today’s
biggest challenges.
Smart manufacturing connects previously siloed
processes. It creates a single view of operations
and enables seamless communications across
Food and Beverage Industry | 3
Mix.
The power of your information
Smart manufacturing capitalizes on the latest
technological advances to re-define what
manufacturing can be.
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The Internet of Things, the proliferation of
smart devices connected via the Internet
Protocol, allows you to access data that until
now has been trapped in your machines,
processes & supply chain.
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Wireless and mobility technologies enable
data to be accessed and captured from
nearly anywhere, and create new ways for
communications and collaboration to occur.
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Big data and data analytics help you
manage massive amounts of data from
across your enterprise and contextualize
it into actionable information.
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secure network infrastructure based on
A
industrial Ethernet protocols, such as EtherNet/IP™,
supports seamless, real-time data sharing and
communications across your enterprise.
“Sensor data that are used to predict
when equipment is wearing down or needs
repair can reduce maintenance costs by
as muchas 40 percent and cut unplanned
downtime in half.” 1
Working together, these technologies give you
unprecedented ability to access, analyze and
act on data from your operations. In order to get
the most from them, however, you must first
converge your IT and plant-floor systems into a
single network architecture.
A converged network architecture helps simplify
how systems operate and streamlines the
coordination of data from a variety of sources
across your operations. Rockwell Automation
calls this The Connected Enterprise.
1 An Executive’s Guide to the Internet of
Things, McKinsey & Company, August 2015
Food and Beverage Industry | 4
Flavors.
What can Smart Manufacturing do for you?
Bringing together disparate networks, improving
production visibility and attaining better
control of your processes can help you make
operational improvements and drive gains in
efficiency, especially for complex activities like
changeovers. Additionally, wider availability of
information can help you be more responsive
to supply-chain developments and improve
on-demand production.
In particular, smart manufacturing can help you:
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Improve asset utilization
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Increase yield
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Drive workforce productivity
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Optimize resource management
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Mitigate security risks
“By linking machines, production lines,
operators and support services, smart
manufacturing can help companies to
optimize their business processes to a level
that could previously only be imagined.” 1
1 Is Smart Manufacturing the Food Industry’s Next Revolution? Food Online, July 21, 2015
Food and Beverage Industry | 5
Appetizing.
Improve asset utilization
Better Intelligence
Enhanced Control
Manufacturing information is the basis for deeper
analysis to improve operations. Integrated systems
and coordinated data from a variety of sources
are transforming food and beverage production.
For example, the ability to access real-time
information on parameters, such as temperature,
pressure, cook time and clean-in-place, can help
you create a more proactive approach to food
safety and quality. Automated data collection,
logging and reporting also can help reduce your
regulatory compliance burden.
A modern distributed control system (DCS)
integrates all of your automation processes
into one plantwide system. DCS features,
such as model predictive control (MPC), alarm
management and batch management, can
help improve plant efficiencies and operational
performance. Virtualized servers and workstations
can help reduce IT investments, improve uptime
and extend life cycles.
Enterprise manufacturing intelligence (EMI)
software organizes, correlates and presents
production information to help operators
spot issues and adjust in real time. Data-rich
dashboards display how a machine or line is
performing, and notifications alert workers if
production parameters exceed preset limits.
Chocolate maker Barry Callebaut used
manufacturing intelligence software to track
OEE and notify operators of product losses
as they occurred via an ingredient-tracking
dashboard. The facility turned material
losses into a net gain.1
Smarter Machines
Smart machines and devices can provide
unprecedented access to the most powerful
element that too few food and beverage
producers fully capitalize on: their own data.
Real-time data can be logged and analyzed
to help workers make better decisions and
ultimately optimize not only their machines,
but their entire manufacturing process.
1 Barry Callebaut Finds Sweet Savings With OEE Solution, IndustryWeek, Sept. 26, 2015
Food and Beverage Industry | 6
Filling.
Increase yield
Smart manufacturing provides opportunities to:
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F ollow the flow of ingredients and track yield
throughout production
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Monitor key production areas and use insights
to improve operations
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Respond to supply-chain developments to
improve on-demand production
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Help prevent and manage recalls
Manufacturing execution system (MES)
software automates data collection for deeper,
more immediate production visibility. This can
help you make better decisions based around
your operations, the commodity market and
raw ingredients to help manage material
variance and improve yield.
It also can provide the foundation for a strong
food safety/quality system and help track
ingredients. Traceability within the food supply
chain is becoming essential to efficiently
respond to consumer demand, or help prevent
and manage recalls.
EMI software can consolidate data from many
sources within your operations, and provide
reporting and analysis to help drive yield. Quality
managers can review production events and
monitor work cells to track first-pass yield. Plant
managers can monitor yield as part of their
plantwide data and metrics tracking.
Line-integration systems enable you to
configure, control and analyze line performance
from a standard operator station so you can
more quickly deploy and optimize production
equipment.
MPC software uses predictive models to
calculate optimum set points during
production. Then, it continuously monitors
multiple parameters to help you maximize
equipment performance and better manage
complex processes.
A major powdered milk processor used
MPC to reduce moisture variability levels
in its dryers by an average of 52 percent.
This resulted in an average yield increase
of one ton per day.
Food and Beverage Industry | 7
Stir.
Drive workforce productivity
Food and beverage producers of
all sizes face many of the same
challenges, including the need
to improve productivity, help
protect workers and preserve the
knowledge of retiring employees.
Smart manufacturing can help you
manage these challenges.
Workforce Utilization
Access to real-time data that is
contextualized and relevant to the
work being performed can create
'frictionless' productivity. This can
help food and beverage companies
be more responsive to work-flow
needs and reduce time-to-market.
Workforce Safety
Safety systems that are integrated
with machinery control systems
can help mitigate risks and are not
as prone to nuisance shutdowns
as older hardwired systems.
Additionally, data on safety incidents
can help you identify risks and make
adjustments in areas where safetyrelated shutdowns are occurring.
Hillshire Brands implemented a
manufacturing intelligence system at its
Haltom City, Texas, plant, which produces
58 varieties of meals on a stick. The system
gives operators insights into where problems
are, where they may arise, and where
additional production capacity exists.
The improved visibility helped the plant
reduce inedible product and waste goals to
0.8 percent – or annual savings of about 5.5
million corn dogs. Additionally, the system
provides improved traceability and reporting
for compliance with new regulations under
the Food Safety Modernization Act (FSMA).1
1 Case Study: Hillshire Brands Mobilizes Information to Improve Compliance, Reduce Quality Deviations and Waste Background, Food Manufacturing, May 18, 2015
Food and Beverage Industry | 8
“Over the next decade nearly 3.5 million
manufacturing jobs will likely need to be
filled. The skills gap is expected to result in
2 million of those jobs going unfilled.” 1
Workforce Availability
As older, more experienced workers retire,
younger, less experienced workers are taking their
place. Operations should be future-proofed with
this in mind.
Worker-specific instructions and contextualized
production information can help reduce
complexity for these new workers, and mobile
devices can deliver information to them in an
interactive, familiar format. Digitizing processes
also can capture critical “tribal knowledge” of
experienced workers before they retire.
You can also leverage outside services to
augment your existing workforce when
qualified talent isn’t locally available.
Some examples include the following:
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T hird-party, remote-monitoring services can
provide continuous machine monitoring, data
collection and live support if your maintenance
team is understaffed and overwhelmed. These
services can be especially valuable for critical
processes, round-the-clock operations and
operations that are based in remote locations.
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E mbedded engineering services can help
keep operations running smoothly should
staffing challenges arise. Factory-trained field
service professionals can provide dedicated
engineering support and maintenance
services, and complement the skills of your
existing workforce.
1 The Skills Gap in U.S. Manufacturing 2015 and Beyond, Deloitte, 2015
Food and Beverage Industry | 9
Prepare.
Create a Future-Ready Workforce
In smart manufacturing
operations, productivity is
increasingly dependent on the
network technologies and data
analytics. You need to be sure
your workers have the knowledge
and skills necessary to design,
maintain and support the network
infrastructure. They also must be
able to capitalize on the data that
can keep your lines running longer
and improve productivity.
The convergence of IT and plantfloor systems combined with the
changing technology landscape is
blurring the roles and responsibilities
of IT and operations personnel.
This presents challenges for you to
be sure workers have the skills and
knowledge they need to maximize
network uptime and get the most
from your data.
1 2014 Food, Drink and Consumer Goods Industry Outlook Survey, KPMG, 2014
Training and certification services
can help re-skill your workers for
converged environments and an
influx of data. Introductorylevel courses give workers the
foundational skills they need to
manage and administer networked
industrial control systems. More
advanced courses dive deeper into
topics, such as industrial Ethernet
protocols, wireless technology
implementation and advanced
troubleshooting.
Nearly two-thirds of food,
drink and consumer-goods
company executives said
sourcing and retaining key
talent will be a significant
challenge in the next one to
three years.1
Food and Beverage Industry | 10
Measure.
Optimize Resource
Management
Improved productivity can be a corollary benefit
when you use smart manufacturing to address
other areas of need. One of those areas is the
management of resources, including water, air,
gas, electricity and steam (WAGES).
Energy management is a key example. Food
and beverage consistently ranks high among
U.S. manufacturing sectors when it comes to
energy usage. As a result, organizations want to
maximize their return on this controllable cost.
Smart technologies can make energy data
more easily accessible and increase visibility to
help make smarter decisions when it comes
to controlling energy usage. Armed with these
capabilities, food and beverage manufacturers
can proactively manage load requirements,
improve system performance and reduce costs.
Food Producer Reduces Energy and Water
Usage as Part of Production Overhaul
A U.S. canned-foods producer upgraded
its automation infrastructure to meet
production and sustainability needs.
The new controls run a state-of-the-art heat
and energy-recovery system, which re-uses
100 percent of the can-cooling process
heat to warm city water for the soaking,
blanching and cooking procedures. The
result: a 38.2 percent decrease in natural
gas usage.
The system also re-uses cooled water to
reduce the temperature of the cans in the
cooking process. This has cut down on the
company’s overall water usage by more
than 100 million gallons each year.
Meanwhile, the company is producing the
same amount of product in five days that
used to take seven, while achieving a better
product quality, too.
Food and Beverage Industry | 11
Layered.
Mitigate Security Risks
For all the benefits that smart manufacturing can offer
your operations, it also requires a more comprehensive
approach to security. Seamless connectivity and smart
devices are the catalysts to smart manufacturing – but
they can also be a conduit for security threats.
Some considerations to keep in mind when developing
an industrial security program include:
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Begin with a security assessment to identify your
risk areas and potential threats.
Network security is critical for any smart manufacturing
enterprise. In the food and beverage industry, you
need to protect not only your uptime and intellectual
property but also the processes, equipment and
people responsible for keeping your products safe
and high quality.
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Apply a multi-layered security approach such as
defense-in-depth security to establish multiple
fronts of defense using physical, electronic and
procedural safeguards.
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Leverage the technologies across your operations
in a way that optimizes security.
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Use resources – such as the Converged Plantwide
Ethernet (CPwE) reference architectures from
Rockwell Automation and Cisco.
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eploy the appropriate security efforts for new
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technologies, such as using mobile device
management to restrict and monitor mobile access.
Your security program should be holistic. It should
extend from the enterprise, down to the plant level,
and out to all end devices. And it should address risks
across your people, processes and technologies.
“As more food and beverage
industry operations become
automated, security risks,
such as data/recipe theft
and hacker-caused plant
shutdowns, are becoming
headaches for engineers.” 1
Kaspersky Labs found that
21 percent of manufacturers
suffered an intellectual
property loss within a oneyear period.2
1 Rockwell, Cisco Launch New Architectures to Reduce Security Risks, Food Engineering, July 28, 2015
2 Kaspersky Lab Survey: One in Every Five Manufacturing Businesses Has Lost Intellectual Property to Security Breaches Within the Past Year, Kaspersky Labs, Aug. 13, 2014
Food and Beverage Industry | 12
Ready.
Smart manufacturing has the potential to
wholly transform food and beverage
manufacturing operations.
The ability to access relevant, real-time and
role-based information can enable more
informed decision-making at every level and
create nearly endless opportunities for you to
improve processes. Additionally, advances in
equipment, control systems and information
systems can help you establish more flexible
and more responsive operations.
And the benefits of smart manufacturing extend
far beyond operational improvements. A secure
network infrastructure, greater connectivity
and access to actionable information also create
opportunities to enhance quality, food safety and
worker safety – helping to reduce your regulatory
compliance burden.
To learn how smart manufacturing can help improve
your operations, contact your Rockwell Automation
sales representative or learn more here.
EtherNet/IP is a trademark of ODVA Inc.
Food and Beverage Industry | 13
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Publication FOOD-SP025A-EN-P - November 2016
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